Plastics material and method of producing said material

ABSTRACT

A combustion resistant material which will not produce toxic gases when subjected to heat, and which can be formed by moulding or by coating it onto a receiving surface whilst its constituents are reacting is produced by reacting a mixture of: 
     62 to 76:percent by weight aluminium oxide or hydroxide 
     12 to 16:percent by weight phenol resin 
     11.5 to 17.5:percent by weight furfuryl alcohol 
     with sulphonic acid which serves as hardener, the proportion by weight of the sulphonic acid being from one-tenth to one-twentieth of the amount of aluminium oxide. The viscosity of the reaction mixture can be adjusted by addition of thinners such as butanol or butylglycol, or of thickeners such as chalk, particulate silicic acid, talc or magnesium oxide.

This is a division, of application Ser. No. 046,012, filed June 6, 1979.

BACKGROUND OF THE INVENTION

This invention relates to a non-combustible material which does notdevelop toxic fumes, when subjected to heat based upon phenol resins andfurfuryl alcohol.

Heat-hardenable plastics moulding preparations based on phenol resinsand furfuryl alcohol are already known from German Auslegeschrift No. 1144 474. The moulding preparations described therein, which are intendedto have a high tolerance in the shaping operation and a high hardeningspeed, do not however possess the properties, hereinafter described,which are characteristic of the materials of the invention.

BRIEF DESCRIPTION OF THE INVENTION

The new material in accordance with the invention is characterised inthat it has been obtained by reacting a mixture of 62 to 76 percent byweight of aluminium oxide, 12 to 16 percent by weight of phenol resinand 11.5 to 17.5 percent by weight of furfuryl alcohol with sulphonicacid, with the sulphonic acid present in such an amount that theproportion by weight of sulfonic acid groups amounts to approximately1/10th to 1/20th of the amount of the aluminium oxide, with subsequenthardening.

In accordance with a preferred embodiment, the material contains, inaddition to the aforementioned reaction product, up to 3 percent byweight of finely-particulate silicic acid, up to 0.5 percent by weightof inorganic glass frit, up to 0.4 percent by weight of hardenedpolyester resin and up to 0.5 percent by weight of hardened epoxy resinindividually or in a mixture.

The material can be produced as a shaped or moulded body having a densestructure, for example as a slab or as hard foam or coating on anydesired substrate. In this form it serves advantageously as a buildingcomponent material or roofing material and as a protective materialwherever absolute non-combustibility and safety against the developmentof poisonous fumes is required.

The method of producing the material in accordance with the inventionincludes reacting a mixture of 62 to 76 percent by weight aluminiumoxide, 12 to 16 percent by weight phenol resin and 11.5 to 17.5 percentby weight furfuryl alcohol with sulphonic acid as a hardener and thismixture is, prior to hardening, either introduced into a mould or isapplied as a covering or coating to a substrate. The combination of themixture with the sulphonic acid is an exothermic chemical reaction as aresult of which the temperature can rise to 110° C. or above.

The amount of sulphonic acid to be admixed depends, on the one hand, onthe desired hardening speed, but on the other hand on the type ofsulphonic acid used. The amount of sulphonic acid is to be so selectedthat the proportion by weight of sulphonic acid groups amounts toapproximately between 1/10th and 1/20th by weight of the amount of thealuminium oxide used in the preparation. Phenol sulphonic acids and,particularly phenol-4-sulphonic acid are advantageous in the practice ofthe invention.

A particularly advantageous material in accordance with the invention isachieved if the aluminium oxide is replaced wholly or partially byaluminium hydroxide (Al(OH)₃). This provides a material which is betterresistant to fire in that water vapour or steam will be given offsimultaneously with decomposition of the aluminium hydroxide into analuminium oxide, along with consumption of heat, so that the temperatureof the material is reduced and the oxygen concentration at the surfaceis reduced by the escaping water vapour. Both phenomena act in anadvantageous manner on the combustion behaviour of the material.

It has proved to be advantageous to admix with the mixture, to improvethe mechanical and chemical properties, additionally up to 0.4 percentby weight unsaturated polyester resin and up to 0.5 percent by weightepoxy resin. If one adds, with this proportion of resin, appropriateamounts of hardeners specific to the resins, then these resins hardenwith the overall composition.

The reaction mixture is, even after the addition of the sulphonic acid,a flowable viscous liquid, which can easily be filled into moulds. Theviscosity of the reaction mixture can be influenced within wide limits,either by adding thinning agents such as butanol or butylglycol inamounts of a few percent by weight of thickening agents such as chalk,finely divided silicic acid, finely divided aluminium oxide, talcum ormagnesium oxide. The increase in the viscosity is of importanceparticularly when it is desired to impart to the reaction mixture, priorto the hardening, a paste-like consistency, in order to apply it tosubstrates for the purposes of forming a covering layer which hardensthereon. Thickening agents can also be admixed with the sulphonic acid.For example, the sulphonic acid can be added in the form of a paste tothe mixture, which has been thickened with chalk. Also, in accordancewith a particularly preferred embodiment, the sulphonic acid serving ashardener or polymerisation agent can be replaced wholly or partially byparaformaldehyde.

The reaction mixture can also be blown prior to hardening, so that ahard foam is obtained. For this purpose, the mixture is admixed withappropriate amounts of blowing agents, such as fluorocarbon compounds,fluorochlorocarbon compounds and/or sodium bicarbonate. The amount ofblowing agent is, of course, governed by the volumetric weight which isdesired to be achieved in the resulting hard foam.

A material having particularly favourable properties in accordance withthe invention is prepared by using a mixture composed of 64.5 percent byweight aluminium hydroxide, 13 percent by weight phenol resin, 13percent by weight furfuryl alcohol, 0.4 percent by weight unsaturatedpolyester resin, 0.45 percent by weight epoxy resin, 2.2 percent byweight paraformaldehyde, 1.4 percent by weight each butanol and ethanol,2.2 percent by weight butylglycol, 0.4 percent by weight glass frit and2.8 percent by weight finely divided silicon dioxide reacted with amixture composed of 16 grams phenol-4-sulphonic acid and 5 grams chalkper 100 grams of aluminium hydroxide, and the composition, prior tohardening, is either applied to a substrate to form a coating or isintroduced into a mould. This mixture can also be used to produce arigid foam, by adding to the mixture, for each 100 grams of aluminiumoxide, 0.05 to 0.3 grams of sodium bicarbonate and from 6 to 30 grams offluorochlorocarbon, and by allowing it to foam in an open mould prior tohardening.

The material in accordance with the invention, after reaction, withinwhich condensation and polymerisation reactions appear to take place,contains the components in a ratio which is optimum for the desired fireprotection properties. This ensures that upon combustion or carbonationthe organic constituents are retained as insulating or isolating carbonlayers in a basic matrix of aluminium oxide, so that the body, or thefoam, retains its structure and shape, without combustion productsliquifying and/or dropping off or destroying the structure. Moreover,these firmly-adhering carbon layers form a reliable and durableinsulation against undesirably high heating of the inner parts of thestructure. Since the material in accordance with the invention does notcontain any halogen or antimony compounds of any kind, as are customaryin many materials for similar purposes, no toxic components of any kindarise in the fumes resulting from combustion or heating to hightemperatures. In addition, the material also displays considerableheat-insulating and sound-insulating properties.

EXAMPLES

The invention will be explained further in the following examples, inwhich all of the given percentages are by weight:

EXAMPLE 1

A mixture of 71 percent finely-particulate aluminium oxide, 12.5 percentfurfuryl alcohol, 15 percent phenol resorcinol resin, 0.5 percent epoxyresin, 0.5 percent finely-divided silicic acid (such as that knowncommercially under the trademark "Aerosil") and 0.5 percentparaformaldehyde are intimately mixed with 7 grams arylsulphonate per100 grams aluminium oxide. A pasty composition is obtained which isapplied as a coating of 1 mm thickness on roof beams and theresolidified after about 10 minutes in a form-holding manner and after afurther 25 minutes, is completely hardened.

EXAMPLE 2

Work is carried out as in Example 1 above with the difference that 36percent of the aluminium oxide is replaced by aluminium hydroxide(Al(OH)₃). Here, too, a coating is obtained which is absolutelynon-combustible and does not develop any toxic fumes when subjected toheat.

EXAMPLE 3

A mixture "A" is produced from:

100 grams aluminium hydroxide (alumina hydrate), 20 grams phenol resin,20 grams furfuryl alcohol, 2 grams ethanol, 2 grams butanol, 3 gramsbutylgylcol, 3 grams paraformaldehyde, 4 grams finely-particulatesilicic acid (Aerosil®), 0.6 grams glass frit, 0.6 grams epoxy resin,containing 6 percent by weight hardener constituent, 0.5 gramsunsaturated polyester resin, and 3 percent by weight benzoyl peroxide ashardener. This mixture, which is still flowable, is caused to react witha mixture "B" consisting of 16 grams phenol-4-sulphonic acid and 5 gramschalk. Directly afterwards, the mixture is cast in a wooden mould toproduce slabs measuring 100 cm×20 cm×2 cm. The temperature of themixture rises up to 110° C. in the course of the next 4 to 5 minutes.After 30 minutes, the composition is solidified to such an extent thatit can be removed from the mould; after 120 minutes it is completelyhardened. When studying the fire behaviour in accordance with theFederal German Republic Standard No. DIN 4102, test pieces made fromthis composition displayed a critical oxygen content (COI) of 100percent, a criterion for absolute non-combustibility.

To increase the strength properties still further, strengthening andreinforcing agents can be introduced into the slabs.

EXAMPLE 4

The same preparation as in Example 3 was, prior to the hardening afterthe adding together of the mixtures A and B, additionally mixed with0.05 grams of sodium bicarbonate and 6 grams fluorochloro hydrocarbon(such as that known under the trademark "Frigen") and cast into an openvessel. After hardening, there was obtained a rigid foam with avolumetric weight of about 500 grams per liter, having cells closedsubstantially to liquid penetration, i.e. a closed cell foam.

I claim:
 1. A method of producing a non-combustible material which doesnot develop toxic fumes when subject to heat, comprising:reacting amixture of(a) 62 to 76 percent by weight of aluminium oxide or aluminiumhydroxide; (b) 12 to 16 percent by weight of phenol resin; and (c) 11.5to 17.5 percent by weight of furfuryl alcohol with (d) a hardening agentin such an amount that the proportion by weight of the hardening agentfunctional group amounts to about 1/10th to 1/20th of the amount of thealuminium oxide, and prior to hardening is applied to a substrate orintroduced into a mould.
 2. The method of claim 1 wherein said aluminiumhydroxide is present at a level of 62 to 76 percent by weight.
 3. Themethod of claim 1 wherein said hardening agent is a sulphonic acid. 4.The method of claim 3 wherein said sulphonic acid is phenol-4-sulphonicacid.
 5. The method of claim 1 wherein said hardening agent isparaformaldehyde.
 6. The method of claim 1 wherein said hardening agentis admixed in mixture with chalk or silicon dioxide in finely dividedform.
 7. The method of claim 1 wherein the reaction mixture is blown byadding a blowing agent selected from the group consisting offluorocarbon compounds, fluorochlorocarbon compounds and sodiumbicarbonate, or mixtures thereof, prior to the hardening.
 8. The methodof claim 1 including up to 0.4 percent by weight unsaturated polyesterresin with 3 percent by weight benzoyl peroxide, up to 0.5 percent byweight epoxy resin including an effective amount of hardener, up to 3percent by weight finely divided silicic acid and up to 0.5 percent byweight glass frit admixed with the mixture prior to the reaction.
 9. Themethod of claim 1 wherein a mixture of 64.5 percent by weight aluminiumhydroxide, 13 percent by weight phenol resin, 13 percent by weightfurfuryl alcohol, 0.4 percent by weight unsaturated polyester resin,0.45 percent by weight epoxy resin, 2.2 percent by weightparaformaldehyde, 1.4 percent by weight each butanol and ethanol, 2.2percent by weight butylgylcol, 0.4 percent by weight glass frit and 2.8percent by weight finely divided particulate silicon dioxide, is causedto react with a mixture of 16 grams phenol-4-sulphonic acid, 5 gramschalk to 100 grams aluminium hydroxide, and the composition, prior tohardening, is applied to a substrate or introduced into a mould.
 10. Amethod as claimed in claim 7 characterised in that the reaction mixtureis blown by adding 0.05 to 0.3 grams sodium bicarbonate and 6 to 30grams fluorochlorocarbon per 100 grams as aluminium oxide.